Cement bound aggregate masses



j Patented May 22, 1951 CEMENT BOUND AGGREGATE MASSES Corwin D. Willson, Flint, Mich.

No Drawing. Substituted for application Serial No. 568,385, December 15, 1944. This application December 22, 1947, Serial No. 193,336

2 Claims. 1

This invention relates to cement-bound fibrous-aggregate materials, and this application is a substitution for my application Serial No. 568,385, filed December 15, 1944, now abandoned, the latter application being a continuation in part of my copending applications, Serial No. 485,642, filed May 4, 1943, now abandoned, and Serial No. 506,772, filed October 18, 1943. It is an object of this invention to provide a composition which is formed of aggregate materials and which has characteristics which render it highly resistant to damage from fire, water, rot, .and insect attack and which is also highly weather resistant. The material under consideration is the type which may be mixed much as present day concrete is mixed and which may be formed into various building units and other articles by proper molding methods.

It is a further object of the present invention to provide an aggregate mix, using standard high earl strength Portland cements as the BEBE g material together with an adfix consisting of high alumina cement, calcium sul Hate and calcium chloride. On the other hand, t e ag -gregates used are not those used in ordinary concrete But are preferably inert organic materials Another object of the invention is 9. Portland cement bound mass of aggregate material, some organic; the mass containing, in addition to the calcium sulphoaluminate constituents of the or an cemen 0 er cons 1 uen s 0 ca 0mm sulghoaluminate and of di'fierent type and m t e orin of an admixture; and the mass comprising other compatible ingredients added to effect such physical characteristics of the mass as the density, elasticity thereof, and the thermal insulation efficiency, and the resistance to fire and water, and tensile and compressive strengths relative to the porosity and the like.

These and other novel features and objects of the invention, hereinafter to be more fully described and claimed, are intended to supply the present lack of a suitable low-cost, light-weight, and load-bearing composition for thermally insulative fire-safe and weather-resistant building construction: a composition that may be i or panels or blocks, or that may be poured or sprayed or applied with a trowel, and that may comprise largely such farm, forest and industrial wastes as are available in wide variety throughout the world. I

The various features of the invention are best such as saw dust, shavings, straw, and so forth.

formed by hand or machine processes into boards understood by citing a number of examples of compositions made according to the invention:

Example 1 5 For comparison, two batches were mixed: the

first having an admix according to the invention'mitrthe second without admix. The first batch contained 825 g. 1131," 275g. h earl strength Portland cement, 120 ml. water and 13 g. a mix e second batch contained 825 g. san g. high early strength Portland cemeiit and 120 m1; water. Weight of the cement in the second batch thus equalled the combined weight of the cement and admix of the first 15 batch. Each batch was molded into test specimens having the form of standard briquettes and 2" cubes. After final set, these were cured for seven days in very moist a l; and drie o hours in an oven at??? degrees rage dry weight of specimensbtthfirt batc containing the admix was: briquettes, 134 g. each; cubes, 275 g.; and of the second batch without admix: briquettes, 135 g. each; cubes, 276 g. The specimens were then tested on standard apparatus for tensile and compressive strengths. These were, for the first batch, tensile stress p. s. i., 472; comp. stress p. s. i., 7037; and for the second batch without admix, ten. stress p. s. i., 455; comp. stress p. s. i., 6855. Admix A comprised 10 parts hi h a1 en con taining 5-3 and 3-5 calcium aluminates 3 parts natural cement, 10 parts ac vated xite nes m 70 per cent alumina heat-treated to remove some of the h a mu par s en: may, 1 part aluminum sul hate, 3 parts calcium chloride 1 part time and i part salicyclic acid.

Example 2 For comparison, two batches were mixed: the

- first containing 107 g. wood wool, 60 g. shortfibered asbestos, 260 g.

an cemen 00 ml.

e second batch admix T07 g. pine wood wool, 60 g asbestos, 293 g. 7 high early strength Portlancl cement and 400 ml. water. The results of tests made on'batch specimens molded and cured and dried in the man ner described for the previous example were: for specimens containing admix, ten. stress p. s. i., 382; comp. stress p. s. i., 1833; for specimens without admix but with added cement, ten. stress p. s. i., 322; comp. stress p. s. i., 1445. Average dry weight first batch specimens was:

briquettes, 51.3 g., cubes, 107.2 g.; and of specif less. Admix B contained 15 parts high alumina 5 corn stallfs', rasses, reeds, leaves, an

Eest 5- mens without admix but with added cement: briquettes, 52.3 g., cubes, 108.8 g. Strengths of specimens containing the admix, as in Example 1, were the greater even though weights were cement containing 5-3 and 3-5 calcium alumI- hate, 5 parts calcined clay, 5 part5 uncalcinea au a cheap term of ca 1 part ac 1va e aluminum sultate used in treatment of sewage,

par calcium or e.

Eidniple s 55 g. cottonwood wool, 25 g. stoneground yelibere as es s, g.

low ine fiber, 30 g. short high early strength Port. and cement, 400 ml.

water and 32 g. admix C were mixed, molded, cured, dried and este as previously described and 'refiilt'sof the tests were: ten. stress p. s. i., 433; comp. stress p. s. i., 1933. Weight of the cubes from this batch averaged 111 g. and of the briquettes, 51.5 g. Admix C comprised 15 g. "2

1 5 g. hosphoric acid.

In more than a thousand different batches comprising the stable calcium sulphoaluminate constituents admixture here being described, it was found that by varying the amounts and kinds of aggregate materials and the addition of compatible leavening and hardeninlg agents, the water- I cemen raig and the like a a amily of compositions resulted which differed in strengthweight ratio according to the followifi'gTEBlE From this table, it is apparent that the ratios of weight to compressive strength of these compositions is 1 to 40 compared with a ratio of 1 to 20 for standard concrete; and the ratio of weight to tensile strength of these compositions is 1 to 8 compared with a ratio of 1 to 2 for standard concrete. In other words, these compositions, relative to weight, are twice as strong in compression and four times as s rongin n'silestress' as stanaardmmsfiipmson becomes even more striking if made between these compositions and concrete of the standard type made from light weight aggregates such as ped slag and vermiculite. In fact, no other light-weight, weat er-proo tions made without pressure and having these low densities, have ever demonstrated anywhere near these strengths.

The following organic materials can be used in the mixes above described: saw dust, hammerortland cement bound composi- 7 milled planer shavin s, scrarfi exce. i 0 r, wood pul and shredded wgg from ax sh ves," cotton lint ers and stalks, rain hulls, nut husks and shells, grain straws, palmetto fiber, Bagasse and cuhh. It Is reat t ese organic aggre- Em's'with mild alkali ora weak solution of barium h dFoxlHe and a solution 0 a um 0 remove mes.

of an alk 1 na hthalene sulfonic acid.

The important contrihution that I feel I have made to the art of weather-proof corn ositions formed of Portland cement and E5 rous or amc aggregates IS the addition to the Portland cement in er of an admix consisting basically of: N. I -r I A high alumina cement (Lumnite) gr."

) A sulphate of aluminum or calcium A chloride or oxychloride of calcium Study of the batches tested indicated that where these comprised a preponderant bulk of organic ingredients, the Portland cement binder varied from 2 to 5 times the weight of the organic aggregates while being but a fraction of their bulk. Effective blending of the organic fibers with V to A by weight of inorganic fibers permitted less cement to be used to attain a desired strength with a corresponding decrease in weight. The admixture constituents varied relative to their strength and proportions in the admixture and relative to the kinds of aggregates and brands of cement used. A fibrous bound mass of low density obviously had larger voids and could withstand a greater internal growth of calcium sulphoaluminate crystals than could a very high-density mass of rigid aggregate ingredients that lacked such voids. (Contrast Example. 1 above with Examples 2 and 3.) Experiment proved that my admixture in its sim lest form. might comprise only high alumina cement,

'affitafining 5-3 and 3-5 ca cium alumina es, and

a sulphate such as aluminum or calcium sulphates since in aqueous solution these constituenfilould reac one W1 e 0 er to the stable ty% of calcium sulphoaluminate above descri e owever, quic er results were secured by the addition of mranderssafi as aluminum or calciumchlqride o'f'calEYum oxychlofi'deI Still' .bttrgesults were secured wlirthe"admixture also included a h eat -treated high alumina clay such as activated bauxite, and'taw of'col 1 9 21191 Suchis l n aita' u fiil y drags. idWhere the fibers used leaned toward the aci s e or where the'Portland cm lacked tree lime, the ad ni xi rre constituents inmall amount of lime. words, the proportions of admixtmnstituents were varied in adaptation o varia es 111 e other ngre cents o e oun fiaigj'ifi'ttfifi 5 instances the high alumina cement exceeding the amount of heat-treated high alumina clay and in other instance vice versa within the limits of the following formula:

0 Parts by weight High alumina cement Heat-treated clay 15 to 5 Raw clay 1 to 5 ulphate /2 to 3 7 Chloride 2 to 8 L1 ewise, norgamc llers such a clay, diatomaceous earth, fl N In other P/ The exact effect of the heat-treated clay, such as activated bauxite, and the raw or colloidal clay, such as bentonite or aluminum hydrate, is not known. Of course, the alumina in these clays will react in time with any free lime in th mixture and with the sulphate to form calcium sulphoaluminate. But experiment shows that even where there has not been sufficient time for appreciable amounts of calcium sulphonaluminate to have been formed in this manner, the clays noticeably increase the strength of the molded specimens. The raw clay appears to assist in the colloidal dispersion and gel-forming quality of the admix. This may be an important factor where a quantity of admix, which should be from 5 to Lper cent by weight of admix relative to e Portland cement *used in a specll'ic batch, is to be dispersed intimately throughout the mass in a few minutes of mixing. And it may be that the clay, in batches containing organic fiber aggregates, helps to coat the fiber in a manner increasing the adhesion of the matrix as it dries.

What I claim is:

1. A strong lightweight weather-resistant bound mass of aggregate material including vegetable f ber dispersed in a hard-set binder above 80 per cent thereof comprising Portland cement and from 5-15 per cent comprising an admixture having the approximate formula: high alumina cement by weight, 5-15 parts of the admixture; high alumina clay, -5 parts; raw clay, 1-5 parts; calciu e, -3 parts; and a c loride of calcium, 2-8 parts. L

2. A strong lightweight weather-resistant bound mass of aggregate material including vegetable fiber and mineral fiber dispersed in a hardset binder above per cent thereof comprising Portland cement and from 5-15 per cent comprising an admixture having the approximate formula: high alumina cement by weight, 5-15 parts of the admixture; high alumina clap, 15-5 parts; raw clay, 1-5 parts; calcium sulphate, /23 parts; and a chloride of calcium, 2-8 parts.

CORWIN D. WILLSON.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,157,234 Lester Oct. 19, 1915 1,194,926 Anderson Aug. 15, 1916 1,422,337 Catlett June 11, 1922 1,460,643 Curtis July 3, 1923 1,521,813 Hornstein Jan. 6, 1925 2,043,249 Jones June 9, 1936 2,057,330 Eichert Oct. 13, 1936 2,121,087 Labra June 21, 1938 2,264,336 Scripture Dec. 2, 1941 2,271,443 Schuh Jan. 27, 1942 2,432,971 Ruthman Dec. 16, 1947 FOREIGN PATENTS Number Country Date 244,178 Great Britain 1925 780,747 France 1935 202,785 Switzerland 1939 843,851 France 1939 OTHER REFERENCES Lea and Desch: The Chemistry of Cement and Concrete, E, Arnold, London, 1935, p. 187. 

1. A STRONG LIGHTWEIGHT WEATHER-RESISTANT BOUND MASS OF AGGREGATED MATERIAL INCLUDING VEGETABLE FIBER DISPERSED IN A HARD-SET BINDER ABOVE 80 PER CENT THEREOF COMPRISING PORTLAND CEMENT AND FROM 5-15 PER CENT COMPRISING AN ADMIXTURE HAVING THE APPROXIMATE FORMULA: HIGH ALUMINA CEMENT BY WEIGHT, 5-15 PARTS OF THE ADMIXTURE; HIGH ALUMINA CLAY, 15-5 PARTS; RAW CLAY, 1-5 PARTS; CALCIUM SULPHATE, 1/2-3 PARTS; AND A CHLORIDE OF CALCIUM, 2-8 PARTS. 